Carboxylic-nitrile-acrylate ester coating composition, process and coated product



United States Patent CARBOXYLI'C-Nl'IRILE-ACRYLATE ESTER COAT- ING 'COMYOSITION, PROCESS AND COATED PRODUCT No Drawing. Application October 26, 1955 Serial No. 543,031

17 Claims. (Cl. 117-103) This invention relates to resinous polymers, and to their use for sanitary protective coatingson containers and closures for foods and beverages, and other applications. This application is a contin11ationin-part of my application Serial No. 269,326, filed January 31, 1952, and now abandoned.

Sanitary coatings are required for successful packing of foods and beverages in containers. purpose may be a single coating, or a finish, size or other coating in a series of successively baked on multiple coatings, and may be applied to a backplate, tinplate, aluminum or other metal surface on the interior or exterior of a container or closure for foods or beverages or the like. The commercial practice of reducing the thickness of tin coatings to a minimum increasingly places a premium on developing high quality coating compositions which can protect the underlying steel base, since the steel base is more susceptible than tin to chemical attack, and must be protected against such attack wherever there might happen to be a break in the continuity of the tin coating. Among the important characteristics sought in sanitary coating compositions are solubility in common solvents, with low viscosity and good flow properties at substantial solids concentrations; thermal stability capable of withstanding high baking temperatures and successive bakings when multiple coatings are applied; dry adherence and flexibility when coated on metal sheets, so that the coating will adhere and not rupture when the sheet is precoated and subsequently fabricated into containers, closures or other articles; adherence under wet as well as dry conditions when coated on metal; the property of A coating for that not imparting flavor to the contents of a container when used as an interior coating on the container or closure; and the ability to withstand the effects of pasteurization, sterilization and other forms of preservation by heat, such as steam processing, when used as an interior coating on a container or closure. The coating should also have sufiicient thermal stability to withstand the heat of solder ing operations on adjacent portions of the article on which it is coated. Although various known polymers have particularly good properties with respect tovarious ones of the above stated requirements, it is nevertheless recognized that it is difiicult to develop coating compositions which achieve a satisfactory balance of the desired properties, and that it is particularly difficult to develop coatings which have l) the useful qualities of insolubility and infus ibility characteristic of thermosetting resins, and also (2) sutficient flexibility, adherence and tenacity to survive intact when precoated on a metal sheet which is subsequently shaped and drawn, as in thecase of fabrication into containers, closures or other articles.

The polymers of the invention provide sanitary coatings having an improved balance and combination of qualities, including flexibility and tenacity suited for fabrication, and insolubility and stability affording high chemical and heat resistance. The polymers of the invention are thermosetting per se, i. e., the application of heat crosslinks the chains of the polymers, and thereby sets or cures the polymers without the aid of any additional agent. Before they thermoset the polymers are fusible and soluble, so that they can readily be applied in solution, and after they thermoset the polymers become relatively insoluble and infusible, and chemically inert. A further characteristic of importance lies in the fact that metal surfaces coated with the cured polymers of the invention can be soldered together readily, without. interference from the coating, as would be expected in the case of the usual baked-on coatings, especially those which are considered to be thermosetting.

The polymers of the invention are formed by the reaction of the following three components in the following proportions:

1) Component A, in proportions of about 5-27 mole percent, consisting of the following alpha-beta ethylenically unsaturated carboxylic acids and anhydrides and mix tures thereof:

Acrylic acid Methacrylic acid Itaconic acid Crotonic acid Monobutyl maleate Monomethyl maleate Maleic anhydride Itaconic anhydride (2) Component B, in proportions of about 35-59 mole percent, consisting of the following alpha-beta unsaturated nitrile compounds and mixtures thereof:

Acrylonitrile Fumaronitrile (3) Component C, in proportions of about. 30-52 mole percent, consisting of esters of acrylic acid and mixtures thereof; e. g.:

Methyl acrylate Ethyl acrylate n-Butyl acrylate lsobutyl acrylate Z-ethyl hexyl acrylate Isooctyl acrylate n-Octyl acrylate lsodecyl acrylate Isotridecyl acrylatc Methoxyethyl acrylate Butoxyethyl acrylate The above proportional limits were determined on the basis of tests both inside and outside of the specified limits for the purpose of determining the ranges of proportions which produce successful sanitary coatings meeting the above described requirements. Since the polymer reaction is capable of a high yield (above it is assumed that the proportions of the components in the polymers remain substantially what they were in the starting charge. I have found the following adverse effects when the specified limits are exceeded (the test methods are described in a later portion of the specification):

(1) Component A: If decreased substantially below mole percent, there is evidently not enough cross-- linking with component B, and tests for process blush become unsatisfactory.

(2) Component A: If increased substantially above 27 mole percent, the excess earboxylic acid content makes the coatingtoo hydrophylic, and process blush tests become unsatisfactory; also,the viscosityis such as to chains evidently become too great; specifically, fabrication testsbecome unsatisfactory, and the viscosity becomes such as to require very strong solvents.

-(5') Component C: If decreased substantially below .30-rnole percent, the internal plasticizing action of com- .ponent C evidently becomes too little; specifically, fabrication tests become unsatisfactory, and the viscosity be- .comessuch as to require stronger solvents.

(6) Component C: If increased substantially above 52 mole percent, the other components A and B are evidently diluted excessively so that they do not cross-link and cure sufficiently, with the result that the coating tests .in general become unsatisfactory, particularly process blush and acetone resistance. .The above-listed different species of the components A and B are substitutable for each other on a molar percentage basis for the purposes of the invention. The above-listed species of component C are also substitut able on a molar percentage basis, but for best results I prefer to use relatively large amounts of lower molecular weight species of component C and to substitute the higher acrylate esters for the .lower acrylic esters on a weight percentage basis. Substituting in that manner produces more uniform results, since the higher acrylate esters tend to soften the polymer and substituting on a weight basis has the effect of reducing the molar proportions as higher acrylate esters are substituted, with a resultant offsetting of their softening effect.

The polymer of the invention is preferably produced with the aid of a catalyst in order to reduce the reaction time, but a catalyst is not essential to the reaction. Azodiisobutyronitrile and benzoyl peroxide are two examples of useful catalysts for the purpose, in proportions by weight of 0.5 to 5% of the combined weight of the components A, B and C. Other catalysts may be selected from known vinyl polymerizing catalysts, such as organic oxidizing agents which contain the peroxide linkage O-O, and azo compounds.

The temperature and pressure conditions for making the polymers of the invention are not precisely limited, but for practical purposes are in the range of to 150 C. at atmospheric pressure. The time for making the polymers of the invention can vary from a few minutes to several days, depending on the temperature and pressure, the yield sought, and the catalyst used, if any.

. While the yield can be carried above 90% by continuing the polymer reaction for a long enough time, a lower yield may be preferred for the most reliable results. The temperature for curing applied films of the polymer can range, for practical purposes, from 250 to 600 F., with the time of cure varying inversely with the temper ature. As the proportion of the above-mentioned component A is reduced, a higher temperature is necessary to thermoset the polymer in a given time period.

The polymers of the invention are preferably produced with the aid of a suitable solvent to lower the viscosity of the components as they polymerize and to obtain a good reaction producing a high yield ofv auniform polymer, but the solvent is not essential to the reaction. Any solvent may be selected which is a good common solvent for the reactants in their original state, and for the completed polymer, and which does not prevent or enter into the polymer-producing reaction. Examples of such solvents are the following, including mix tures thereof: aromatic hydrocarbon solvents such as benzene, toluene and xylene, ethyl benzene, isopropyl benzene and commercial mixed aromatic hydrocarbon solvents (mixed with more active solvents when using lower molecular weight acrylic esters as component C); ether alcohols, such as ethylene glycol monobutyl ether, ethylene glycol monomethyl ether, diethylene glycol monobutyl ether, diethylene glycol monomethyl ether, and diethylene glycol monoethyl ether; ketones, such as methyl ethyl ketone and methyl isobutyl ketone; and such solvents as cycloh-exanone, diacetone alcohol,-'acetone, dimethyl formamide, ethyl acetate and butyl propionate.

Solvents suitable for use with the polymers of the invention to make coating compositions are any of those mentioned in the preceding paragraph, and others Selected from those suitable for vinyl polymers in general, e. g., isophorone. I have found that an important advantage of the use of higher molecular weight acrylic esters as component C lies in the fact that they permit the use of substantially larger proportions of aromatic hydrocarbon solvents in the solvent for purposes of forming coating compositions with desired qualities of viscosity and flowout at given solids concentrations, than in the case when lower molecular weight acrylate esters are used for component C. For example, the highest percentage concentration of any aromatic hydrocarbon solvent with isophorone for polymers with ethyl acrylate as component C is about 65%, whereas as high as 100% may be used in such a solvent mixture with isooctyl acrylate as component C. When thinned to the neces: sary degree with solvents such as those mentioned, the polymers of the invention may be applied by brushing, roller coating, spraying and other conventional means.

Illustrative examples of polymers embodying the inventionare as follows:

EXAMPLE I EXAMPLE II A mixture of 5 grams of glacial acrylic acid, 30 grams of distilled acrylonitrile, 65 grams of distilled isooctyl acrylate, 100 grams of xylene and one gram of benzoyl peroxide are heated at 80 F. for 4 hours. An 80% yield of polymer is obtained, having a viscosity of 40 seconds at 24% total solids in a solvent of 91% xylene and 9% dimethyl formamide at F. in No. 4 Ford Cup, and a viscosity of 30 seconds at 17% total solids in xylene solvent at 80 F. in No. 4 Ford Cup.

The excellent thermal stability of the polymers of the invention is illustrated by the fact that test coatings of the polymers of Examples I and II, applied without primer on blackplate, survive in good condition, as evidenced by substantially unchanged color, when baked for 24 hours at 400 F.

The following table shows the results of testing coatings of the polymers of Examples I and II, and also the results of. like tests on other polymers consisting of only two of the three constituents of the Example I polymer, in order to indicate the importance of having all three con stituents in the polymer.

Table of test data Polymer (Components in Parts by Weight) Example X Y Z Example I II Polymer Components:

Acrylic acid (A) 5 5 6 Acrylonitrile (B) 30 0 30 3O 30 .Ethyl acrylate (C) 65 i 65 65 0 Isooctyl aerylate (C). 65 Percent total solids 26 30 28 I0 24 Coated at 5 mgJsq. in. on unprimcd specimens baked 10 min. at 400 F., and (i D db 1 (10 i f t) rye eson sperec on ETP 10 10 10 10 10 on HP 10 10 10 10 10 (ii) Acetone resistance (10 is perfect)- on ET Insol. Sol. Sol Insol. Insol. on BP Insol. Sol. Sol Insol. Insol. (iii) Fabric on ET 24 22 25 6 21 on HP 26 26 10 27 (iv) Process blush resistance (10 is per ct) on ETP 8 0 6 a 8 on BP 6 6 5 6 v 8 (v) Ppocgfs wet adhesion (10 is per I eo on ETP 10 10 10 0 10 on. BP 10 1 10 0 10 The polymers used in the tests stated in the above table were dissolved in methyl ethyl ketone, except in the case of the Example II polymer, which was dissolved in 91% xylene and 9% dimethyl formamide. After being dissolved in such solvents to the total solids stated in the table, each polymer had a viscosity of substantially 40 seconds in No. 4 Ford Cup at 80 F., and was roller coated on electrolytic tinplate (ETP) and blackplate (BP) specimens, which were unprimed. The specimens were baked as stated in the table, and were then tested. The test procedures are outlined as follows:

(i) Dry adhesion: The coated surface of the specimen is cross-hatched with a blade and then pressure-sensitive tape (Scotch tape) is applied and rapidly pulled off to determine whether any of the coating was removable.

(ii) Acetone resistance (insolubility): The coated surface of the specimen is wiped with an acetone-impregnated pad, to determine whether the coating is soluble or insoluble in acetone. This is a measure of the extent to which it has thermoset.

(iii) Fabrication: The coated specimen is fabricated into a can end or closure, and the specimen is then immersed in a copper sulfate solution for one minute to indicate any exposed metal. The coating is then inspected for adherence and continuity.

(iv) Process blush resistance: The coated specimen is treated with steam or hot water in an autoclave under pressure for a period of 30 minutes, and is then visually inspected for blush, i. e., a whitening, blistering, spotting or dulling of the coating.

(v) Process wet adhesion: After treating and inspecting the coated specimen for process blush, the specimen is blotted dry and tested for adhesion in the same manner as stated above for dry adhesion.

Pigments, dyes, Waxes and other non-reactants may be added to the composition of the invention for decorative purposes and the like, without otherwise materially affecting the significant characteristics of the composition. In addition, the polymer of the invention may be modified with additives to enhance special properties.

The preferred esters of acrylic acid for component C are listed above, but other esters of acrylic acid can be used, such as aryl esters of acrylic acid (e. g., phenyl acrylate), aryl alkyl esters of acrylic acid (e. g., benzyl acrylate), and cycloalkyl esters of acrylic acid (e. cyclohexyl acrylate).

While I have described present preferred embodiments of the invention and methods of practicing the same, it

will be recognized that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

I claim:

1. The process which comprises copolymerizing in solution in non-reactive organic solvent, monomer components A, B and C at a temperature in the range of C. to 150 C. in the presence of a free-radical generating polymerization cataylst to obtain a copolymer which is soluble in said organic solvent and which is thermosetting per se, said components being in proportions in the copolymer of about 5-27 mol percent of component A, 35-59 mol percent of component B, and -52 mol percent of component C; and component A being a compound selectedfrom the group consisting of acrylic acid, methacrylic acid, itaconic acid, crotonic acid, monobutyl maleate, monomethyl maleate, maleic anhydride and itaconic anhydride, and mixtures thereof; component B being a compound selected from the group consisting of acrylonitrile and fumaronitrile and mixtures thereof; and component C being an acrylate ester.

2. The process of claim 1 in which said acrylate ester is selected from the group consisting of methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, 2-ethyl hexyl acrylate, isooctyl acrylate, n-octyl acrylate, isodecyl acrylate, isotridecyl acrylate, methoxyethyl acrylate and butoxyethyl acrylate, and mixtures thereof.

claim 1.

4. A solution comprising non-reactive organic solvent containing dissolved therein a copolymer made according to the process of claim 1.

5. The process which comprises copolymerizing in solution in non-reactive organic solvent, at a temperature in the range of -20 C. to 150 C. in the presence of a free-radical generating polymerization catalyst 5-27 mol percent of acrylic acid, 35-59 mol percent of acrylonitrile and 30-52 mol percent of an alkyl acrylate to obtain a copolymer which is soluble in said organic solvent and which is thermosetting per se.

6. The process which comprises copolymerizing in solution in non-reactive organic solvent, at a. temperature in the range of 20 C. to 150 C. in the presence of a free-radical generating polymerization catalyst 5-27 mol percent of methacrylic acid, 35-59 mol percent of acrylonitrile and 30-52 mol percent of an alkyl acrylate to obtain a copolymer which is soluble in said organic solvent and which is thermosetting per se.

3. A copolymer made according to the process of 7. The process which comprises copolymerizing in solution in non-reactive organic solvent, acrylic acidf'acry lonitrile and ethyl acrylate at a temperature in the range.

of 20 C. to 150 C. in the presence of a free ratdiall.. v generating polymerization catalyst to obtain a gopolymer which is soluble in said organic solvent and 'which'is thermosetting per se, said monomer components-being 'in proportions in the copolymer of about 5-27 mol percent of acrylic acid, 35-59 mol percent of acrylonitrile and 30-52 mol percent of ethyl acrylate.

8. The process of claim 7 in which said acrylic acid,

acrylonitrile and ethyl acrylate respectively are present in proportions in the copolymer of substantially 5, 30, and 65 weight percent, respectively.

9. The process which comprises copolymerizing in lution in non-reactive organic solvent, acrylic acid, acrylonitrile and isooctyl acrylate at a temperatu'r'ein the' range of C. to 150 C. in the presence of a freeradical generating polymerization catalyst to obtain, a

copolymer which is soluble in said organic solvent and which is thermosetting per se, said monomer components being in proportions in the copolymer of about 5-27 mol percent of acrylic acid, 35-59 mol percent of acrylonitrile, and -52 mol percent of isooctyl acrylate.

10. The process of claim 9 in which the said acrylic acid, acrylonitrile and isooctyl acrylate respectively are present in proportions in the copolymer of substantially 5, 30 and 65 weight percent, respectively.

11. The process of obtaining a durably adhesive protective covering on a metallic sheet which comprises coatingsaid sheet witha copolymer made by copolymerizing in solution in non-reactive organic solvent components A, B and C at a temperature in the range of -20 C. to 150 C. in the "presence of a free-radical generating polymerization catalyst to obtain a copolymer which is soluble in said organic solvent and which is thermosetting per se, said components being in proportions in the polymer of about 5-27 mol percent of component A, 35-59 mol percent of component B, and 30-52 mol percent of component C, component A being a compound selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, crotonic acid, monobutyl maleate, monomethyl maleate, maleic anhydride and itaconic anhydride, and mixtures thereof; component B being a compound selected from'the group consisting of f acrylonitrile and fumaronitrile, and mixtures thereof; and

component C being an acrylate ester; and thereafter heatingthe coated sheet to temperature in the range of 250 to 600 F. and converting the coating to the thermoset condition in the absence of any extraneous cross-linking agent.

12. The process of claim 11 in which said acrylate ester is selected from the group consisting of methyl acrylate, ethyl' acrylate, n-butyl acrylate, isobutyl acrylate,

2-ethyl hexylacrylate, isooctyl acrylate, n-octylacrylate,

acrylate, respectively.

16. The process of claim 11 in which the said components A, B and C are acrylic acid, acrylonitrile and isooctyl acrylate, respectively, in proportions in the copolymer of substantially 5, 30 and weight percent, respectively.

' 17. A coated metal article made by the process of claim 11. 1

References Cited in the file of this patent UNITED STATES PATENTS Hagedorn et al. Nov. 20, 1934 2,231,407 Castor et al. Feb. 11, 1941 2,436,926 Jacobson Mar. 2, 1948 2,772,166 Fowler Nov. 27,1956

2,787,603 Sanders Apr. 2, 1957 1 FOREIGN PATENTS 665,479 Great Britain Jan. 23, 1952 674,728 Great Britain July 2, 1952 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,873,211 I February l0, 1959 Gerald P. Roeser It is hereby certified that error appears in the-printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 3, lines 59 and 60, for 2O to 150 C read -20 to 150 C Signed and sealed this 23rd day of June 1959.

(SEAL) Attest: I

KARL H. AXLINE ROBERT C. WATSON Commissioner of Patents Attesting Officer 

11. THE PROCESS OF OBTAINING A DURABLY ADHESIVE PROTECTIVE COVERING ON A METALLIC SHEET WICH COMPRISES COATING SAID SHEET WITH A COPOLYMER MADE BY COPLYMERIZING IN SOLUTION IN NON-REACTIVE ORGANIC SOLVENT COMPONENTS A, B AND C AT A TEMPERATURE IN THE RANGE OF -20* C. TO 150* C. IN THE PRESENCE OF A FREE-RADICAL GENERATING POLYMERIZATION CATALYST TO OBTAIN A COPOLYMER WHICH IS SOLUBLE IN SAID ORGANIC SOLVENT AND WHICH IS THERMOSETTING PER SE, SAID COMPONENTS BEING IN PROPORTIONS IN THE POLYMER OF ABOUT 5-27 MOL PERCENT OF COMPONENT A, 35-59 MOL PERCENT OF COMPONENT B, AND 30-52 MOL PERCENT OF COMPONENT C, COMPONENT A BEING A COMPOUND SELECTED FROM GROUP CONSISTING OF ACRYLIC ACID METHACRYLIC ACID ITACONIC ACID, CROTONIC ACID, MONOBUTYL MALEATE, MONOMETHYL MALEATE, MALEIC, ANHYDRIDE AND ITACONIC ANHYDRIDE, AND MIXTURES THEREOF; COMPONENT B BEING A COMPOUND SELECTED FROM THE GROUP CONSISTING OF ACRYLONITRILE AND FUMARONITRILE AND MIXTURES THEREOF; AND COMPONENT C BEING AN ACRYLATE ESTER; AND THEREAFTER HEATING THE COATED SHEET TO TEMPERATURE IN THE RANGE OF 250* TO 600* F. AND CONVERTING THE COATING TO THE THERMOSET CONDITION IN THE ADSENCE OF ANY EXTRANEOUS CROSS-LINKING AGENT. 